• MERCURY SWITCH BOXES


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  • FileName: mercign.pdf [read-online]
    • Abstract: MERCURY SWITCH BOXESMercury Switch Boxes Mercury CDM Modules114-2803 (6 Cyl.) 114-7509 CDM ModuleReplaces 332-2803A3, and A4. Replaces:827509A1, A3, A4, A7,

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MERCURY SWITCH BOXES
Mercury Switch Boxes Mercury CDM Modules
114-2803 (6 Cyl.) 114-7509 CDM Module
Replaces 332-2803A3, and A4. Replaces:827509A1, A3, A4, A7,
CDI’s switch box and ignition coil A9, A10, T7
are attached to a mounting plate
CURY
MER CUR Y
for easy installation.
MERCUR
This unit is a replacement to the
original case. It does not contain
a rev limiter or tach circuit. 114-7509K1 CDM Module Adapter
Kit
114-2986 (4 Or 6 Cyl.) Replaces: 822779A2, 5,A10, A12,
Replaces 18-5779, 332-2986A3, A4, A13, A14 AND 817509A6, A12.
A5, A7, A8, A9, A10, A17, A21, A22, A23,
A24, A25, and Kit includes 114-7509 CDM module,
A27. CDI’s switch box and ignition coil mounting hardware and instructions
are attached to a mounting plate for
easy installation. 511-7509K6 CDM Module Test
This unit is a replacement to the
Kit
original case. It does not contain a
tach circuit. Original cases can be Test kit contains 6 - 114-7509
special ordered with tach circuit ($10 CDM Modules and a 511-5207A1
surcharge). CDM Test Harness.
114-2986K1 (4 Cyl. Kit Only)
Replacement kit for R337-4411
switch box and R337-4406 trigger.
Kit includes 114-2986 switch box,
134-3736 trigger, 4 cylinder wheel,
spacer, and bearings. Mercury Switch Boxes
Shaft and rotor not included.
114-4953 (3 Cyl.)
114-4796 (3 Cyl.) Replaces 18-5790, 18495A10,
Replaces 332-4796A3, and A6. CDI’s A12, A18, A19, and A26.
switch box and ignition coil are attached 114-4953-32 (3 Cyl.)
to a mounting plate for easy installation. Long Wires
This unit is a replacement to the
Replaces 18495A22, 18495A32.
original case. It does not contain
a tach circuit. Original cases 114-9052 (3 Cyl.)
can be special ordered with tach Replaces 18-5791, 19052A1,
circuit ($25 surcharge. A2, A3, A5, A6 and A8.
944-9215A29 Spark Plug Wire (1 pc)
114-5772 (4 Cyl.)
Replaces: 84-99215A25, 84-99215AA29,
Replaces 18-5881, 332-5772A1,
84-813715A 1.
Distributor type spark plug wire has a A2, A3, A4, and A5.
threaded end to connect to the distributor
114-6866 (4 Cyl.)
cap.
Replaces 332-826866A2.
114-4911 (2 Cyl.) 114-7778 (3 Or 6 Cyl.)
Replaces 18-5786, 18-5787, 332- Replaces 18-5775, 332-
4911A2, A5, A8, and 338-4733A2 5524, 332-7778A1, A3,
(requires wire splicing). A5, A6, A9, and A12.
114-4952 (2 Cyl.) NOTE: Plastic case helps reduce the possibility of
Replaces 18495A4, A5, A6, A8, A11, internal arcing and shorting between cases.
A13.
114-4952A30 (2 Cyl.) Mercury Inductive Ignition Coil Wires
Replaces 18495A9, A14, A16, A20, 934-1945 (6 wire set)
A21 and A30. Inductive replacement for
114-6222 (2 Cyl.) 815358A1and 821945T65 spark plug
Replaces 18-5788, 18-5789, 339- wires help reduce RFI interference
5287, 339-6222A1, A4, A6, A8, and A10. and “Ghost” problems.
34 QUICK STRIKE IGNITION PRODUCTS • TECH SUPPORT: 866-4-CDI-TECH • FAX: 256-772-5701
SWITCH BOXES-VOLTAGE REGULATORS
SWITCH BOXES-VOLT
XES-VOL REGULAT
Mercury Switch Boxes R336-4516 (R&R)
Replaces:333-4516A2
114-9052 (3 cyl) This module uses 994-3981
Replaces:19052A1, A2, A3, A5, A6, insulator blocks
A8
R332-4172 (2 Cyl) (R&R) 994-4463
MER CUR Y
MER CUR Y
MERCUR Y
MER CURY
MER CUR Y
Replaces:332-4172 Condensor
Replaces:336-4463
R333-3213 (4 Cyl) (R&R)
Replaces:333-3213
Mercury Rectifier
R338-4733A2 (2 Cyl) (R&R)
Replaces: 338-4733A2 154-6770
Note: 114-4911 (wires) can be used in Replaces: 18-5708, 332-2910,
place of 338-4733A2 62351, 78614, 816770
114-7452K1 (2 Cyl)
Replaces:18-5777, 18-5778, 339- Mercury Voltage Regulators
7452 A1, A7, A8, A9, A10, A11, A14,
194-5279
A15, A21 (Wires) New Case Design
Replaces: 18-5741, 18-5742, 18-
114-7452A3 (2 Cyl) 5743, 18-5744, 815279; 815279-
Replaces:18-5776, 339-7452 A2, 1, 2, 3, 4, 5; 815279T, T2, T3, T4,
A3 (Terminals) T5;
114-5713 (2 Cyl) 815279A1, A2, A3; 817411;
Replaces:855721A3, A4 830179, 830179-2; 830179A1,
A2, A3; 830179T; 854514A1,
Mercury Rev Limiter 854515, 854515T 1, 856748,
144-1889-51 Rev Limiter (5200 RPM) 65W-81960-00-00, 883072,
Replaces:821889A19, 821889A22, 883072 1 & 883072T.
821889A29, 821889A34, 194-2115K1
821889A40, 821889A42, Replaces: 194-3072K1, 854515T
821889A45,821889A46, 821889A50 2, 883072T 1, 883072T 2 and
and 821889A51. 893640-002.
144-1889-52 Rev Limiter (5800 RPM)
Replaces:821889A6, 821889A36, 194-5279-R
821889A44, 821889A48 and Replacement Rectifier/
821889A52 Regulator for the 194-8736K1
Conversion Kit
144-1889-30 Rev Limiter(5600 RPM)
Replaces:821889A20, 821889A27 194-8736K1 (40 Amp) Regulator
and 821889A30 Kit
144-1889-55 Rev Limiter (6600 RPM) Replaces:18736, 18-5824. Kit
Replaces:821889A54 and includes (2) 194-5279, plate and
821889A55 gasket,
Requires 4 yellow wire stator!
Mercury Oil Warning Modules Note: This kit is also available with the
174-9610A18 stator kit
144-1470-25
194-8825K1 Mercury
Replaces:41470A2, 41470A3,
Voltage Regulator/Rectifier
41470A4, 41470A11, 41470A12,
Replaces:88825A 7
41470A15, 41470A19, 41470A20,
41470A21, 41470A25, 41470A26
an 41470A27 Mercuiser Voltage Regulators
144-4857-16 R99502A4
Replaces:14857A6,14857A10, 3/4” Pipe, Mercruiser Voltage
14857A11, 14857A12, 14857A13, Regulator (R&R)
14857A15 and 14857A16 Replaces:99502A4, A7, A9, A13
Mercury Control Module R99502A8
R857185T (R&R) 5/8” Pipe Mercruiser Voltage
Replaces 857185A2 and Regulator (R&R)
857185T1. Replaces:99502A8, 99502A12
QUICK STRIKE IGNITION PRODUCTS • TECH SUPPORT: 866-4-CDI-TECH • FAX: 256-772-5701 35
MER CURY TRIGGERS
MERCUR
CURY
Mercury Triggers For Battery Ignitions Mercury Trigger (3 cyl.)
R332-4797 3 Cyl Trigger 134-4512-3 (3 Cyl.)
Replaces: 332-4797 Replaces: 854512T and
994-4603 3 Cyl Rotor 855746A12
Replaces: 337-4603 134-6453 (3 Cyl.)
CURY
MER CUR Y
Replaces: 18-5797, 68162A 3, A 6,
R393-2918 (R&R)
MERCUR
96455A 1, A 8
Replaces: 393-2918
134-7029-3 (3 Cyl.)
134-3736 Replaces: 817029A 3 and
New Design has a replaceable 817029A 9
cap. Requires a STEEL trigger 134-8302-3 (3 Cyl.)
disk. Includes both 4 and 6 cyl Replaces: 828302A 1 and
Steel disks, bearings, spacers, 855745A11
snap ring and instructions. 134-9021-3 (3 Cyl.)
Replaces: 332-4177and 393-3736 Replaces: 99021A 3, A 5, A
994-6406 Snap Ring 8, A13, A15 and A16
Replaces: 56-26406
NOTE: These triggers do not include the linkage
994-6379 Lower Bearing bushing or ball
Replaces: 30-26379
994-0066 Upper Bearing Mercury Trigger (4 Cyl)
Replaces: 30-20066
994-3538 Spacer 134-4513-4 (4 Cyl.)
Replaces: 23-53538 Replaces 834821, 854513T and
855748A2
994-3538-10 Spacer
134-6452 (4 Cyl.)
Same as 994-3536 but 0.010 taller
Replaces:73372A1, 73410A1,
994-4371 Rotor & Shaft 76681A1, 77000A2, 96452A1,
Fits 4 & 6 Cyl engines A4, A5 (Straight arm)
Replaces: 393-4371 and 393-4312 134-6454 (4 Cyl.)
Replaces 77000A1,
Trigger Discs For 134-3736 96453A2 (Hooked arm)
134-3236-S (4 Cylinder) 134-7029-4 (4 Cyl.)
Replaces: 393-3236 Replaces 817029A4 and
817029A11
134-4313-S (6 Cylinder)
134-8303-4 (4 Cyl.)
Replaces: 393-4313
Replaces 828303A1and
855745A22
Mercury Trigger (2 cyl.) 134-9021-4 (4 Cyl.)
R338-4731 (2 Cyl.) (R&R) Replaces 99021A2, 99021A6 and
Replaces: 338-4731A1 A6, A8 99021K2
R98450 (2 Cyl.) (R&R) NOTE: These triggers do not include the linkage bushing or ball
Replaces: 98450A1, A3, A5, A10
134-3960-2 (2 Cyl.) Mercury Trigger (6 Cyl)
Replaces: 853960T and 855747A 1
134-6456 (6 Cyl.)
134-5744-2 (2 Cyl.) Replaces:18-5795, 18-5798,68162A1,
Replaces: 828301, 854509, A5, A8; 96455A6, A9, A10, A11
854509A 9, 855744A 2, 855744A11 134-6456-15 (6 Cyl.)
Replaces:18-5796, 96455A15
134-9021-2 (2 Cyl.) (Barrel Connectors)
Replaces: 99021A11, A14
134-6456-18 (6 Cyl)
134-9527-2 (2 Cyl.) Replaces 96455A18
Replaces: 819527A1 W/6 pin connector
NOTE: These triggers do not include the linkage bushing or NOTE: These triggers do not include the linkage
ball bushing or ball
36 QUICK STRIKE IGNITION PRODUCTS • TECH SUPPORT: 866-4-CDI-TECH • FAX: 256-772-5701
MER CURY HARNESSES
MERCUR
CURY
Mercury Internal Engine Harnesses Mercury Harness Connections Chart
414-2770 The following chart is for the proper connection of CDI’s
Replaces: 37628, 38072, 38920, replacement Mercury harnesses. Please follow the wire
39177, 45070, 46285, 46905, 48150, instructions when using these Harnesses.
MER CUR Y
MER CUR Y
MERCUR Y
49370, 52769, 52770, 52771, 52820,
MER CURY
MER CUR Y
Note: Battery Type and Alternator driven ignitions are
56370, 59741, 84-46463, 84-
62534,84-66055, 84-66297, 84-
different!!!
69236, 84-71443, 84-73826, 84- Normal Connections for Battery Driven Ignitions:
74904 CDI Harness PN’s: 414-2770, 414-3369, 414-5532.
414-3369 CD Module PN’s:
Replaces: 84-64997, 84-73369, 84- Mercury CDI/Rapair
73447 and 84-76295 332-2803 114-2803
414-5532 332-2986 114-2986
Replaces: 34229, 47929, 57022 332-4796 114-4796
and 84-85532 337-4411 R337-4411 (R&R)
Points/Condenser NA
Black 4 AWG Engine Ground
NOTE: The diagrams are of the pin-out of the INTERNAL Black 18 AWG Ground Term.starter solenoid
ENGINE HARNESS - NOT THE BOAT SIDE HARNESS Yellow Start terminal starter solenoid
Gray Choke solenoid
Mercury Cannon Plug Engine Harness Orange Not used (tape off)
414-0043 Replaces 84-850043A 2 White 12V from ignition switch (not use w/ADI)
414-0220A 2 Replaces 84-850220A 2 Yel/Red stripe (2) Jumpers for rectifier-stator terminal block
414-1591 Replaces 84-41591A 3 Brown Tachometer lead
Red 4 AWG Battery side of starter solenoid
414-3443 Replaces 84-43443A 3
414-4614 Replaces: 84-14614A 1 Red (in harness) +(POS) terminal of rectifier
414-6075 Replaces 84-826075A 2 Red Jumper Connect from +(POS) terminal of rectifier
to the red terminal of the battery CD
414-6219A 2 Replaces 84-96219A2
414-6219A 5 module (not used on ADI type ign.)
Replaces 84-96219A5, 84-96219A8
414-6220A 3
Replaces: 84-96220A 2, A 3
414-6220A 4 Replaces: 84-96220A 4 Normal Connections for ADI Ignitions:
414-6220A12 Repl: 84-96220A12 Warning: Do not connect any 12V red wire to these
414-6220A16 Repl: 84-96220A16 switch boxes as severe damage will result.
414-6233A 1
Replaces: 84-96233A 1 Alternator Driven Ignitions
414-6233 A2 CDI Harness PN’s: 414-2770, 414-3369, 414-5532
Replaces: 84-89915A 1, 84-96233A 2 CD Module PN’s:
414-6277 Replaces: 84-96277A 2, A4 Mercury CDI/Rapair
414-8672 Replaces 84-18672A 8 332-4172 R332-4172 (R&R)
332-4911 114-4911
414-9061 Replaces 84-19061A 2
332-5772 114-5772
332-7778 114-7778
Mercury Engine to Boat Adapter Harness
333-3213 R333-3213 (R&R)
421-4401 338-4733 114-4911
Replaces: 84-93669A 2 339-5287 114-6222
Adapter Harness to Boat Harness 339-6222 114-6222
adapts older Mercury engines with Black 4 AWG Engine Ground
through splash pan connector to Black 18 AWG Ground Term.starter solenoid
the newer cannon plug control box. Yellow Start terminal starter solenoid
Gray Choke solenoid
Mercury Universal Boat Harness White Not used (tape off)
474-9550 Orange Kill wire (may be marked black/yellow)
Yel/Red stripe(2) Jumpers for rectifier-stator term. block
Universal Boat Harness; Fits most
(not needed for all applicatons)
outboard application through 1978.
Brown Tachometer lead
Works with all CDI engine
Red 4 AWG Battery side of starter solenoid
harnesses listed above.
Red (in harness) +(POS) terminal of rectifier
474-9560 Red Jumper Not used
Universal Boat Harness; Fits most Black Jumper Connect from switch box ground to
outboard applications from 1979 engine ground.
through 2001. Includes Tilt/Trim
control wiring.
QUICK STRIKE IGNITION PRODUCTS • TECH SUPPORT: 866-4-CDI-TECH • FAX: 256-772-5701 37
MER CURY STAT ORS-COILS
MERCUR STA
CURY
Mercury 2 Cylinder Stators Mercury Stator Coils
Note: Installation instructions included with stators 174-3175 Coil
174-3996 (Red coil only)
Replaces: 18-5855, 336-3962, 336- Replaces: 333-3175
3996
CURY
MER CUR Y
This stator includes 1174-3176 Coil
MERCUR
994-3981 insulator blocks. (Blue coil only)
Replaces: 333-3176
174-6617K1 (Kit) 174-4469 Low Speed (LS)
(Includes stator & instructions) (Coil replacement only)
Replaces: 18-5863, 18-5864, 86617A2, Replaces:336-4467A 1 and 336-
A3, A5, A9, A11, A13, A17, A20 4469A 1
Note: It is recommended that both
174-5721K1 174-4469 and 174-4470 coils be
Replaces: 855721A4, T8 replaced.
174-4793 174-4470 High Speed (HS)
(Battery charge only stator) (Coil replacement only)
Replaces: 398-3587, Replaces: 336-4468A 1 and 336-
398-4792, 398-4793, 4470A 1
398-5232
174-6120K1 Coil Kit
174-5255 (2 replacement coils only)
Replaces: 18-5856, 398-4770, Replaces: 339-5312, 339-5313,
398-5255, 398-5256 339-5589, 339-5590, 339-6119,
339-6120.
174-4424
Replaces: 398-4423, 398-4424
(Includes 154-6770 rectifier.)
Mercruiser Stators
Mercury 40 AMP Stators 174-6231K1 (40 Amp)
174-9610K2 (2 Wire)
Replaces: 398-9610 A3, A5, A6, A9, Replaces: 18-5872, 398-6231A4,
A14, A17, A19, A22, A24, A33 A5, A6, A10
(Single and dual rectifier connections)
398-858404T 4 (R&R) 398-6231A2 (4 Wire) (R&R)
Replaces: 398-858404T3 and 398- Replaces: 398-6231A2
858404T4.
(Used with CDM Modules)
174-9610A18 (Kit)
Replaces: Mercury Misc. Harnesses
398-9610A18
Kit includes 174-9610K2 stator and
194-8736K1 Regulator/Rectifier Kit 451-9601 6 Ft. Extension Cable
To relocate EFI outside of engine
Note: Installation instructions included with stators
Mercury 3.0 Stators 934-8721 Wire set
Switch box to coil Replaces Mercury
R398-821935K1
84-88721A 1 and 84-43442A 3
(R&R only) (4 cyl. set)
Replaces: 398-821935A3
(12 Position connector)
R398-821935K2 934-9738 Wire set
(R&R only) Switch box to coil
Replaces: 398-821935A5 Replaces Mercury 84-69738 &
(6 Position connector with 84-69739 (6 cyl. set)
common ground wire )
38 QUICK STRIKE IGNITION PRODUCTS • TECH SUPPORT: 866-4-CDI-TECH • FAX: 256-772-5701
MERCURY STATORS
MERCUR STA
CURY
6 Cylinder Mercury Stators 3 and 4 Cylinder Mercury Stators
174-5456 (9 Amp - 6 Cylinder only) 174-5454K1 (3 & 4 Cylinder only)
Replaces: 18-5854, 18-5857, Kit includes stator & instructions.
398-5454 A2, A6, A7, A8, A9, A17, Replaces:18-5859, 18-5865, 18-5866,
MER CUR Y
MER CUR Y
MERCUR Y
MER CURY
A18, A55 (6 Cyl.) 398-5454 A21, A22, A24, A25, A26, A42,
A56, A62, A63 (4 Cyl.)
398-5704 A2, A4, A5, A7 (3 Cyl.)
274-5456S15 Special Racing 398-5919 A2, A3, A6, A7, A8, A10
Stator
CUR
(4 Cyl.)
Racing version of 174-5456. Used Note: This stator does not work on 6
in conjunction with special racing cylinder engines.
switch box 114-7778R2.2. Highly Notice: Stators 174-5454K1 and
174-8778K1 are not interchangeable
recommended for engines turning
due to difference in flywheels!
in excess of 8000 RPM.
Replaces: 398-5454S15
2-3-4 Cylinder Mercury Stators
174-5456-16 (16 Amp - 6 Cyl. only)
Replaces: 18-5860, 18-5861, 398-
174-8778K1 (9 Amp Kit)
5454 A11, A15, A16, A30, A31, A32, Kit includes stator, adapter terminals &
A34, A35, A36, A61, A64, A66 (6 Cyl.) instructions.
Replaces: 18-5873, 18-5874, 398-8778 A6,
A10, A16, A17, A18, A21, A22, A23, A24,
274-5456-S35 Special Racing
A25, A26, A27, A28, A29,
Stator 398-818535 A3, A5, A8, A9, A10, A13, A14,
Racing version of 174-5456-16. A15, 749095, F749095
Used in conjunction with special
racing switch box 114-7778R2.2. Note: 174-8778K1
Highly recommended for engines can be used with
turning in excess of 8000 RPM. either a voltage
regulator or a
174-9873-16 (6 Cylinder)
Replaces: 18-5867,
398-9873 A1, A3, A4, A36, A39 174-9710K1 (16 Amp Kit)
Kit includes stator, adapter cables &
instructions.
Replaces: 398-9710 A11, A12, A14,
A15, A17, A18, A22, A23, A25, A28,
2-3-4 Cylinder Special Red Stator Application
A30, A33, A34, A36, A38, A39, A43,
A45, A46, A47, A48, A49,
Use only with CDM Modules (1996 & Newer Engines) 398-9873 A9, A17, A19, A24, A25, A29,
(This is a stator only- It’s not the OEM replacement kit) A35, F747095
174-2075K1 (9 Amp)
(Existing Mercury Red Stator only) Note: 174-9710K1
Replaces: 398-9873A13, must be used with
398-832075 A13, A14 volt.reg. 194-5279
174-2075K2 (16 Amp)
(Existing Mercury Red Stator only)
Replaces: 18-5870, Bullet Connector Kits
398-832075 A3, A4, A5, A6, A9, A12,
A17, A21 911-9783
398-9873 A22, A28 Bullet Connector Kit
Exposed Windings Only!
Notice: We recommend these stators be used with the CDM Contains:
Module systems only. See P/N on page 34. If the engine 10 Male bullet terminals
uses a standard switch box and has the red stator adapter w/boots
installed, remove the adapter and use either the 10 female bullets
174-8778K1 (9 Amp) or the 174-9710K1 (16 Amp) stator.
w/sleeves
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Use: 0.0404